My BearMan inspired maul

[Big Papa Leather]

I took BearMan's inspiration and created my own lightweight maul.

I used some Redheart wood and a 1X30 belt sander to shape the handle.

The head is UHMW plastic rod 2" in diameter. The handle is much thicker than the BK maul I have. I like the BK maul and think it is a fine piece of work, but making my own was fun as well.

I needed a drill press to drill the hole for the carriage bolt that runs through and connects the two pieces.

It weighs in at 12.6 oz. I have only tested the maul on scrap but I am going to use it to make a project this weekend.

It gave me ideas to make a heavier one. I am going to make another head that is hollow to allow the insertion of lead shot to create more weight. It may even give it a "dead blow" effect. The main problem I have is the plastic place requires a $25.00 minimum purchase. That will be a Huge amount of this stuff. I do not plan on going into production of these things so I might just revert to eBay to buy a smaller qty. So if you see Scissormedic bidding don't bid against me

Let me know what you think, and again Bearman thanks for the inspiration!

If anyone has any suggestions on the weighted head please let me know!

[Nocturne]

That's a good looking maul right there, I like it.

Where did you get the material you used for the head?

I've been looking at making my own, and what to use is giving me some trouble.

[McJeep]

That's it - I'm inspired AND cheep like borscht ;0)

Made a call downtown and I can get a foot of the 3" for $16

Time to get the father inlaw working on his lathe and making me up a couple or three nice fat handles for my gimped paws :0) I figger a foot should net me 3 maul heads and we can turn a couple of em down for lighter weight.

how long is the head on the one you made?

Thanks bud!

[Big Papa Leather]

The head on mine is 2" diameter and 2.25" in length.

I am going to pick up some more at the local plastic shop prolly next week.

Interstate plastic is the name. Interstate has alot of locations search them on google and see if one is close to you.

I intend to try and make few more.

Allen

[howardb]

Hints to all:

Pack the lead shot tight or use a brass slug. You do NOT want a dead-blow type maul. I experimented with a DBH and it was an unmitigated disaster. You need a nice sharp impact to dent the leather, not a softened one! Trust me on that...

If you work in a manufacturing environment, get friendly with a local plastics distributor (or find someone who is). Sometimes you can get samples for FREE! And a sample to those guys would make you a handful of mauls! doesn't have to be UHMW. Try Delrin (acetal / POM) for a harder, longer lasting surface. Nylon would work too.

Now all I need is a lathe...

Brent

[sdkid]

Looks like I have another item for the to-do list. Found some delrin on ebay. I'll have to find some nice wood for a handle and try my hand with the lathe.

[asquaregarden]

I took BearMan's inspiration and created my own lightweight maul.

I used some Redheart wood and a 1X30 belt sander to shape the handle.

The head is UHMW plastic rod 2" in diameter. The handle is much thicker than the BK maul I have. I like the BK maul and think it is a fine piece of work, but making my own was fun as well.

I needed a drill press to drill the hole for the carriage bolt that runs through and connects the two pieces.

It weighs in at 12.6 oz. I have only tested the maul on scrap but I am going to use it to make a project this weekend.

It gave me ideas to make a heavier one. I am going to make another head that is hollow to allow the insertion of lead shot to create more weight. It may even give it a "dead blow" effect. The main problem I have is the plastic place requires a $25.00 minimum purchase. That will be a Huge amount of this stuff. I do not plan on going into production of these things so I might just revert to eBay to buy a smaller qty. So if you see Scissormedic bidding don't bid against me

Let me know what you think, and again Bearman thanks for the inspiration!

If anyone has any suggestions on the weighted head please let me know!

How did the UHMW work? Did you have to replace the head? If so after how long?

[whiteeugene]

Great post I was looking at buying a new one this may work just as good and I can get enough material for several I just ordered 1 foot of each type will see witch one works best.

Now if I could get a tool that applied the correct amount of force and automatically kept the spacing correct.

Thanks guys

Doug

Edited December 7, 2012 by whiteeugene

[asquaregarden]

Great post I was looking at buying a new one this may work just as good and I can get enough material for several I just ordered 1 foot of each type will see witch one works best.

Now if I could get a tool that applied the correct amount of force and automatically kept the spacing correct.

Thanks guys

Doug

Keep us posted on your results. I've been doing some research trying to figure out what the best material is. I have some UHMW and i did some testing on it before i even tried making a maul. What I found was that every hit on my stamp left an impression in the UHMW. All the info online as far as i can see(i am not a chemical or mechanical engineer) shows that this material has one of the highest impact resistance. I figured that means it doesn't break not that it doesn't dent. My next try was going to be Delrin. I was reading people's comments on the Bear mauls and they say it doesn't dent. I noticed some of them have brown heads and i did find that they make brown Delrin. I would really like to confirm what they use if anybody has a clue. Any confirmation or suggestion for material would be welcomed.

[mcn]

Looks interesting. McJeep if you can get it for that price would you consider shipping some my way. I would rather pay a member here than some of the prices I saw on Ebay .